Remedy The Hazards of Detonation Spraying

by Imperial Systems | Jan 25, 2016 | Uncategorized

Protect your employees from the hazards of thermal spraying!

Thermal spraying is a coating process that combines a heat source and a coating material in powder or wire form, melts it, and sprays onto surfaces at a high velocity. There are many variations of thermal spraying such as:

• Detonation Spraying
• Plasma Spraying
• Twin Wire Arc Spraying
• High Velocity Oxy-fuel Coating Spraying (HVOF)
• Warm Spraying
• Cold Spraying
• Flame Spraying

Thermal spraying provides wear resistant coatings to protect from erosion and abrasion, and provides different degrees of electrical conductivity. Thermal Spraying has been utilized by many industries such as: Transportation, steel mills, medical, military, computers, aerospace, and many more.

The benefits of thermal spraying are abundant, but execution of the process presents many hazards. The Fabricators & Manufacturers Association, Intl. says that thermal spraying creates toxic dust and fumes due to the atomization of molten metals, posing a dangerous environment for operators carrying out the process.   The Occupational Safety & Health Administration (OSHA) has acknowledged the dangers of explosive gas and carcinogenic fumes from detonation spraying, and recommend implementing their safety standards.  Implementation of a high quality dust and fume collection system and proper ventilation can provide a solution to this hazardous situation.

Solutions For Detonation Spraying Hazards

What can Imperial Systems offer the thermal spraying industry to improve the safety and security of their thermal spraying operators?

Imperial Systems is among the top dust collection equipment manufacturing businesses in North America.  The high quality and efficiency of our CMAXX™ Dust Collection System is how we provide those in the thermal spraying industry with the safety and security they desire.

Our CMAXX™ Dust Collection Systems are  designed with revolutionary PD Technology for maximum cleaning performance and has 10% more filter media than other same-sized vertical cartridge collectors, neutralizing and keeping the air clean while you work. The CMAXX™ dust collector system also allows for 20% more area around the cartridge filters which causes the dust to fall into the hopper before attaching to the filters. Our CMAXX™ dust collector offers these other features:

• Vertical Cartridge Design for a longer filter life
• Internal Velocities are 20% Lower – Best in Class
• Increased Cleaning power with an energy efficient and High-Performance Manifold Mounted Pulse Valves
• Fewer Internal Ledges for Material to Build Up
• Slanted Inlet Design that prevents water build up on the top of the 90° inlet
• Up to 40% More Cleaning Power – Up to Twice the Filter Life
• 15 Year Manufacturer’s Warranty

Combine our quality CMAXX™ dust collector system with our DeltaMAXX™ Replacement Cartridge Filters and you have the solutions to those safety hazard problems.  Our DeltaMAXX™ Replacement Cartridge filters have nanofiber technology that stops submicron particles from embedding into the media, has the highest quality pleated media at a 99.9% efficiency, and are able to reduce the operational cost of your dust collector system with less pulse cleaning.

For more information on our CMAXX™ Dust Collector System and our DeltaMAXX™ Replacement Cartridge Filters contact Imperial Systems today!

5 Pleated Filter Benefits for Dust Collection Systems

by Imperial Systems | Dec 9, 2015 | Uncategorized

Imperial Systems is your go-to resource for safe, effective industrial dust collector systems, filters, and ductwork.

If your business is facing a challenging economic turn, or perhaps is just in a season of slow growth, it can be appealing to try and save money by taking yesterday’s equipment and adapting it to meet today’s increased performance and efficiency standards.  Whether you are investing in a new filter bag house or adapting an old one, Imperial Systems encourages you to consider the following pleated filter benefits for your industrial facility dust collection system.

Today’s air quality standards often require better filtration efficiency than the average traditional bag filter can deliver.  In addition, the type of dust being collected may be so coarse that the media in an older filter can produce holes in the bottom of the bags, resulting in a very short life span for the filter.

Pleated filters are one of the most advantageous dust collector technology innovations in decades.  Because of their numerous benefits over traditional bag and cage technology, pleated filters have won the allegiance of many dust collector operators. In some cases, it is possible to retrofit older dust collectors to use pleated filters.

Here are just a few of the notable pleated filter benefits:

• Operations improvements, including increased productivity, reduced emissions, and lower energy usage and costs.
• Easier installation, resulting in faster changeouts, reduced downtime, and lower labor costs.
• Longer filter life, which reduces replacement costs.
• Fewer filters needed per unit.
• Less compressed air needed to clean filters.

A pleated filter is often a long, slim construction that resembles a cartridge filter.  Pleated bags have built-in cores so they replace both the filter bag and its supporting cage.  Some pleated bag designs even have curved openings at their tops to improve cleaning energy.

Not only do pleated bags look like cartridge filters, but they also perform more like them as well.  The pleated bag filter working continuously offers better efficiency and is often more durable than the polyester felt in a conventional filter bag.  Additionally, the average pleated bag can incorporate much more media material than an equivalent length of the felt bag it replaces, typically allowing substitution of felt bags with much shorter pleated bags.

Imperial Systems is ready to put these pleated filter benefits – or any dust control solution you need – to work for you today. Our customer service representatives pride themselves in providing accurate information, optimal dust control solutions, and outstanding service for our clients.  If you are unsure which option to integrate with your current air purification system, give the experts at Imperial Systems a call at (800) 918-3013.

The IDA Offers NEW Advanced Safety Features YOU Need To Know About

by Imperial Systems | Oct 30, 2015 | Uncategorized

Find out what our IDA has to offer your metalworking business.

If you are in the metalworking or manufacturing industries, safety is, by necessity, one of your highest priorities. From the good keeping and proper use of equipment to consistent use of personal safety gear, there are countless things you monitor each day to keep your employees and your workspace safe.  But are you doing enough?  Or are you at risk for potential combustion due to your dust and fume collection system?

Without IDA (In-line Deflagration Arrester) filters, you and your employees may be at risk. Discover how this proprietary technology from Imperial Systems could prevent disaster in your workshop while reducing your costs and improving your efficiency.

The Danger of Combustion

It’s no secret that dust explosions are a common risk in metalworking and manufacturing industries.  Processes including welding, grinding, polishing, and more can create the perfect combination of dust and sparks in the air that can lead to serious consequences.  For example, three workers were killed in 2010 in a titanium dust explosion in West Virginia.  This incident is in addition to the 281 combustible dust incidents identified by the U.S. Chemical Safety and Hazard Investigation Board between 1980 and 2005.  In those incidents, 119 workers were killed, 718 injured, and many industrial facilities sustained extensive damage.

Recognizing these dangers, OSHA and the NFPA have created standards aimed at minimizing the risks to life and property that are posed by combustible dust.  Important steps to reduce the danger of combustion include:

• Analyzing the hazards present in your facilities
• Utilizing an effective dust collection system
• Monitoring this system and others to ensure proper operation
• Limiting smoking, open flames, and sparks in work areas
• Installing spark arresters in dust collection ductwork

More important combustion prevention guidelines and recommendations can be found with the NFPA or OSHA.

The mistake made by many metalworking and manufacturing businesses is to some, but not all, of the recommended safety steps.  A dust collection system without an IDA present can still combust, creating a deadly flame front.   

Imperial Systems’ IDA Filter Technology

At Imperial Systems, we are proud to announce our proprietary IDA DeltaMAXX filters, which bring advanced safety features to our CMAXX Dust Collection System.  Together, they offer excellent protection against combustion.  

In a recent study of the CMAXX Dust Collector with IDA DeltaMAXX filters, backed by third party testing, we found that in all tests the filters were able to isolate a deflagration and stop a flame front.  The results showed no trace of flame or spark transmission downstream from the filters or in the clean air plenum.  

In fact, the body of the CMAXX Dust Collection System, without explosion venting, was also tested to withstand a deflagration of corn starch at 185 KST with pressures exceeding 4 PSI. In this case, the full explosion diverted through the IDA DeltaMAXX filters.  Afterwards, the filters showed no sign of deformation; their internal cages maintained their shape perfectly, and the seals were not deformed or melted either.  

Note: Although the test described above was performed without explosion vents, as a demonstration of the worst-case scenario, dust collectors should always be properly vented.“discharged into a safe, unrestricted, outdoor location, and the discharge shall not be obstructed” (See NFPA 69 Chapter 12). Where the CMAXX is vented through a pipe or duct, the duct must be designed to withstand the pressure of an explosion. These pressures can be provided at the time of engineering.  Imperial Systems can have your dust tested prior to final engineering to determine the proper venting calculations.  

Comprehensive Combustion Safety

In addition to their high performance in the above testing, the CMAXX Dust Collector with IDA DeltaMAXX cartridge filters also offers several advantages over similar systems that have been tested.  These include:

• Elimination of the need for expensive after-filters that can prematurely blind, causing issues like high-pressure drops, increased filter expenses, additional labor, decreased headroom for indoor applications, and enlarged filter housing.
• Online filter cleaning using the same primary system that the CMAXX uses, ensuring consistent cleaning of the filters during operation
• Compatibility with inline HEPA filters or a remote HEPA filter system as required, unlike other systems which require such filters to be mounted on top of the collector, limiting its flexibility.

The combined features of the CMAXX and IDA DeltaMAXX filters offer metalworkers and manufacturers the quality, safety, and value that we are dedicated to providing here at Imperial Systems.  

Of course, it’s no surprise that together our products demonstrate some of the highest performance on the market, especially when you consider the impressive advantages each has to offer on its own.  For over a decade, Imperial Systems has offered manufacturers and metalworkers like you advanced, reliable dust and fume collection equipment. Just check out the numbers– they speak for themselves!

All of our products also come with the Imperial Systems’ guarantee of outstanding customer service.  We are dedicated to engineering and providing the solutions that manufacturers can rely on for the highest levels of quality, safety, and value.  Whether you talk with our sales engineers or our field crews, we are confident that you will be impressed by our dedication to your service and safety.

If you would like to learn more about any of our products and how they may be able to improve safety and reduce costs in your workplace, please contact us today!  You can reach us at 800.918.3913.

We Want To Hear From You

The particular needs and safety strategies for dust and fume combustion will vary from one workshop to the next.  So, we want to hear from you!  What challenges does your business face when it comes to handling combustible dust and fumes?  What are you currently doing to control the risks?  What solutions are you still looking for?
Let us know in the comments section below; we can’t wait to hear from you!

The Solution to Overpriced Competitor Cartridge Filters

by Imperial Systems | Sep 30, 2015 | Uncategorized

Competitor cartridge filters breaking your budget? Imperial Systems has the solution.

The dilemma is all too familiar.  You need the high performance and safety features provided by competitor cartridge filters for your metalworking shop… but the high price of these filters, which frequently need to be replaced, is draining your budget.  Unfortunately, most lower cost filters you have looked at cannot provide the value and service you really need.  

At Imperial Systems, we believe that metalworkers like you should not have to choose between the safety and service you need and the price you can afford.  So, we are proud to share our solution to overpriced competitor cartridge filters: DeltaMAXX cartridge filters.

Can DeltaMAXX Filters Stack Up Against Competitor Cartridge Filters?

Competitor cartridge filters offer high efficiency and important safety features to keep your metalworking shop safe and clean. If you have a dust collection system, you have confidence that your current filters are a perfect fit.  Can DeltaMAXX really meet the same standards of safety and service?

Absolutely.

Our DeltaMAXX filters are designed to fit every make and model of dust collection system, so you can continue using the system you have in place.  Additionally, our filters meet all OSHA and NFPA safety standards, so you can have confidence in the security provided.

In fact, our filters actually go above and beyond the industry standards.  The DeltaMAXX is one of the highest performing filters in the industry and offers a lifespan up to twice the industry standard, saving you money on frequent replacements.

Going Beyond The Gold Standard

Not only do our filters avoid the high prices of the brand names and frequent replacements, but they also outperform the competition’s filter media.  Using advanced Nanofiber technology, our filters have higher efficiency, fewer emissions, and even reduced cleaning cycles.  Independent lab tests have found Nanofiber technology to be 50% more efficient on .3-1.0 micron particulates than our competition’s.

The Solution You’ve Been Waiting For

Higher efficiency, a longer lifespan, reduced cleaning cycles, and lower costs.  All of these features add up to the solution you have been searching for.  So why wait any longer?  Give Imperial Systems a call today to talk with one of our highly trained service engineers.  

Contact us today at 1-800-918-3013.

competitor cartridge filters | competitor cartridge filter

Cartridge Dust Collectors vs. Other Systems – Best Fit for You?

by Imperial Systems | Sep 11, 2015 | Uncategorized

Imperial Systems offers a detailed step-by-step comparison between cartridge and other dust collector systems.

Every manufacturing environment requires a dust collection system for the health of its workers and the integrity of its machinery and processes.  With so many types and styles, finding the right system for your facility can be a daunting process.  Imperial Systems is here to help with this list comparing the benefits of a cartridge dust collector versus other systems:

Efficiency

Fabric and bag dust collectors lose efficiency as they fill, often beginning to expel fine dust at only half full. A cartridge dust collector uses industrial replacement cartridge filters to create a multi-stage dust collection system. With several filter cartridges in place, they collect more dust and micron particles than other systems, even when the initial stage filter is full. In addition, their process completely removes the dust before it can hit the clean air chamber, so no particles will be blown back into the work environment. Multi-stage filters allow equipment to continue running while the filters are being changed, preventing any disruption in air quality.

Low Maintenance

As a fabric or bag system gets full, its ability to trap fine particulates diminishes, and cleaning the filters can be a hassle – often requiring up to two hours and two people in dust masks for safety. Conversely, the industrial replacement cartridge filters of a cartridge dust collector are removable, so one worker can simply replace all of the filters at once, then clean them at a more convenient time – a process usually completed in less than one hour.

Versatility

Single-stage dust collection systems can only be used in limited production scenarios, but cartridge dust collectors with industrial replacement cartridge filters offer a wide range of applications from pharmaceutical to food to fine metal grinding. With a wide range of sizes and capabilities, cartridge dust collectors come as small as portable downdraft benches and as large as foundry operation systems.

DeltaMAXX industrial replacement cartridge filters

The DeltaMAXX Dust Collector industrial replacement cartridge filters by Imperial Systems deliver the longest filter life, cleanest air and the greatest cost savings through:

• MERV 15 filtration efficiency – the best in the Industry
• Reduced operational costs
• Extended filter life (up to twice as long as competitors’)
• The most advanced nanofiber technology on the market – prevents submicron particles from entering and becoming embed
• Operational Mass Emissions
• The industry’s best surface loading technology – enhances dust cake release, leading to longer filter life
• DeltaMAXX NanoFiber Dust Collector industrial replacement cartridge filters have a very fine surface layer of synthetic fibers that blocks the particulate before it embeds deep into the media.

DeltaMAXX Dust Collector Cartridge Filters are available for all makes and models of cartridge dust collectors and industrial replacement cartridge filters.  In addition to providing superior products, we also provide some of the best service in the industry.  From expert representatives dedicated to solving your dust collection problems to fast shipping and handling, we help you get what you need to keep your manufacturing processes going smoothly.

For more information, contact Imperial Systems today at 800.918.3013.

How Our Dust Extraction Cartridge Filters Exceed Expectations

by Imperial Systems | Aug 26, 2015 | Uncategorized

Tired of being let down? Find out how our dust extraction cartridge filters surpass expectations.

In the metalworking industry, you probably hear promises from a lot of different products every day. However, before purchasing a new product, you need to be able to have confidence that it will live up to your high expectations. Not only is this an important matter for the safety and wellbeing of your employees and workspace, but improper safety equipment can also cost you!  As Shannon Decamp of The Fabricator points out, OSHA continues to crack down on metal fabricators, costing the industry $7 million in citations alone last year.  So, if your shop is looking for high performing dust extraction cartridge filters, you probably want some guarantee that this product will perform before you buy.

At Imperial Systems, we understand; you want to make the best possible choice in dust extraction cartridge filters that you can.  So, we are proud to share a recent case study which demonstrates how our DeltaMAXX cartridge filters surpassed the expectations of a Texas Welding School.

Exceeding Expectations

Perhaps no one knows better than an educational institution the challenge and the necessity of balancing the cost and performance when it comes to safety equipment.  At Texas Community College, the welding technology program was looking for more cost effective cartridge filters for their Lincoln Statiflex 6000 Dust Collector.  However, with the high stakes of students involved, this school also needed a product that they could rely on for the highest level of safety.

Enter the DeltaMAXX Cartridge Filter from Imperial Systems.

After reviewing our literature, the director of the welding program purchased four of these filters. We’ll let him tell you the rest of the story:

“The System is running very smooth, not much back blow. When turning on the dust collector in the past we have had problems with smoke blowing out of the back. That problem went away when we installed the DeltaMAXX filters”, said the Texas welding school instructor.  “Imperial Systems’ dust collector filters are very durable and they are lasting much longer for us. My expectations were exceeded and you can count on us to be a returning customer.”

DeltaMAXX Dust Extraction Cartridge Filters: An Investment In Safety  

We are confident that you will be just as impressed when you make the switch to our dust extraction cartridge filters as well.  Just check out some of the great advantages the DeltaMAXX filters have to offer:

• Up to twice the filter life of the industry standard
• The most advanced Nanofiber technology
• MERV 15 Filtration Efficiency — the best in the industry
• Less pulse cleaning
• Lower operational mass emissions
• Reduced dust collector operational costs
• Highest quality pleated media
• The industry’s best surface loading technology

Ready to find out just how our DeltaMAXX filters will exceed your expectations as well?  Contact us today at 800.918.3013.